US9093705B2 - Porous, amorphous lithium storage materials and a method for making the same - Google Patents
Porous, amorphous lithium storage materials and a method for making the same Download PDFInfo
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- US9093705B2 US9093705B2 US13/837,898 US201313837898A US9093705B2 US 9093705 B2 US9093705 B2 US 9093705B2 US 201313837898 A US201313837898 A US 201313837898A US 9093705 B2 US9093705 B2 US 9093705B2
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
- H01M4/386—Silicon or alloys based on silicon
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B33/00—Silicon; Compounds thereof
- C01B33/02—Silicon
- C01B33/021—Preparation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/052—Li-accumulators
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
- H01M4/134—Electrodes based on metals, Si or alloys
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
- H01M4/139—Processes of manufacture
- H01M4/1395—Processes of manufacture of electrodes based on metals, Si or alloys
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M2004/021—Physical characteristics, e.g. porosity, surface area
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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- Y02E60/122—
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- lithium ion batteries Secondary, or rechargeable, lithium ion batteries are often used in many stationary and portable devices such as those encountered in the consumer electronic, automobile, and aerospace industries.
- the lithium ion class of batteries has gained popularity for various reasons including a relatively high energy density, a general nonappearance of any memory effect when compared to other kinds of rechargeable batteries, a relatively low internal resistance, and a low self-discharge rate when not in use.
- the ability of lithium ion batteries to undergo repeated power cycling over their useful lifetimes makes them an attractive and dependable power source.
- Porous, amorphous lithium storage materials and a method for making these materials are disclosed herein.
- composite particles of a lithium storage material in an amorphous phase and a material that is immiscible with the lithium storage material are prepared.
- Phase separation is induced within the composite particles to precipitate out the amorphous phase lithium storage material and form phase separated composite particles.
- the immiscible material is chemically etched from the phase separated composite particles to form porous, amorphous lithium storage material particles.
- FIG. 1 schematically illustrates an example of a method for making a porous lithium storage material
- FIG. 2 schematically illustrates another example of a method for making a porous lithium storage material
- FIG. 3 is a perspective schematic view of an example of a lithium ion battery, including an example of an anode formed with the porous, amorphous lithium storage material particles disclosed herein;
- FIG. 4 is a scanning electron micrograph (SEM) of a phase separated composite material including tin and amorphous silicon;
- FIG. 5 is a SEM of amorphous, porous silicon that is formed by an example of the method disclosed herein using an atomic ratio of Si 75 :Sn 25 ;
- FIG. 6 is a graph exhibiting the specific capacity and the current efficiency (CE) of an electrode including amorphous, porous silicon particles and a comparative electrode including amorphous silicon/tin particles.
- the high theoretical capacity (e.g., 4200 mAh/g) of silicon renders it desirable for use as a negative electrode material in lithium ion batteries.
- negative electrode materials with high specific capacities also have large volume expansion and contraction during charging/discharging of the lithium ion battery.
- the large volume change (e.g., about 300%) experienced by the negative electrode material during charging/discharging causes silicon particles (used as at least one negative electrode material) to fracture, decrepitate, or otherwise mechanically degrade, which results in a loss of electrical contact and poor life cycling.
- the method disclosed herein results in the formation of porous, amorphous lithium storage material particles which have a large surface area (i.e., ⁇ 100 m 2 /g) and a sufficient amount of free space to accommodate the large volume change during charging/discharging.
- the method disclosed herein results in lithium storage material particles that are able to accommodate the volume expansion and withstand multiple charging/discharging cycles, thus improving the cycling stability and the life of the lithium ion battery.
- the lithium storage material 12 may be any material that can sufficiently undergo lithium insertion and deinsertion.
- Examples of the lithium storage material 12 include silicon and germanium-metal alloys (e.g., Ge—Al alloys, Ge—Ag alloys, and Ge—Sn alloys).
- the immiscible material 14 may be any material that is immiscible in the selected lithium storage material 12 .
- Examples of the immiscible material 14 include tin (Sn), aluminum (Al), silver (Ag), indium (In), and iron (Fe).
- the lithium storage material 12 is silicon and the immiscible material is tin.
- the atomic ratio of the lithium storage material 12 and the immiscible material 14 may be varied, depending upon the desired morphology of the resulting porous, amorphous lithium storage material particles. Altering the atomic ratio enables control over the size of the pores that are formed and the framework of the lithium storage material matrix that is formed. In some examples, the atomic ratio of the lithium storage material 12 to the immiscible material 14 is greater than 1. In these examples, an interconnected lithium storage material matrix having a high percolation value is formed, which includes relatively small pores formed therein. In other examples, the atomic ratio of the lithium storage material 12 to the immiscible material 14 is equal to or less than 1. In these other examples, the immiscible material 14 may be beyond the percolation value, which results in larger, more interconnected pores formed among a less stable lithium storage matrix.
- the selected lithium storage material 12 and immiscible material 14 are melted together to form a mixture 16 , as shown in FIG. 1 .
- the melting temperature will depend upon the melting temperatures of the selected materials 12 , 14 .
- the temperature used to form the mixture 16 will be at least the higher melting temperature of the two materials 12 , 14 .
- the temperature for melting the materials will be at least 1414° C., which is the melting point of silicon. Tin will also melt at this temperature because its melting point is 231.9° C.
- the materials 12 , 14 may be stirred to form a substantially homogeneous mixture of the two materials 12 , 14 .
- a nucleation promoter/additive may be added to the mixture 16 .
- This promoter/additive may be selected to control the precipitation of the immiscible phase during phase separation (discussed below). More particularly, the selected nucleation promoter/additive may increase the nucleation density of the phase of the immiscible material 14 , and thus contribute to a reduction in the pore size and/or the diameter of the porous, amorphous particles that are ultimately formed.
- these nucleation promoters/additives include high melting point materials, such as Si 3 N 4 , SiC, WC, MoC, or the like.
- the nucleation promoters/additives may be in the form of nanopowders having a size (e.g., diameter) below 50 nm. Any suitable amount of the nucleation promoter/additive may be added with a weight ratio below 1%.
- Rapid solidification may be accomplished by cooling the mixture 16 at a rate ranging from about 10 2 K/s to about 10 5 K/s. Cooling may be performed until the composite 18 is formed and has a temperature of about room temperature (e.g., ranging from about 18° C. to about 25° C.). Cooling may be performed using a copper wheel, which rotates at a high speed up to 5,000 rpm. A rotating copper wheel is capable of removing heat very rapidly from the mixture 16 . Cooling may also be performed by exposing the mixture 16 to liquid nitrogen, or some other sufficiently cold liquid.
- the composite 18 that is formed includes amorphous lithium storage material 12 ′ and the immiscible material 14 . While the composite 18 is shown as a layer or film in FIG. 1 , the composite 18 may also be in the form of relatively large particles (i.e., >20 ⁇ m).
- the composite 18 is then exposed to a milling process (shown as “M” in FIG. 1 ) in order to break up the composite 18 into composite particles 20 having a size ranging from about 100 nm to about 20 ⁇ m.
- M milling process
- the milling process further reduces the size of the particles to form composite particles 20 having a size ranging from about 100 nm to about 20 ⁇ m.
- the composite particles 20 also include the amorphous lithium storage material 12 ′ and the immiscible material 14 .
- Milling may be accomplished using ball milling, which involves shaking or milling the composite 18 in the presence of beads. When ball milling is utilized and after mixing is accomplished for a suitable amount of time, the beads are removed and the composite particles 20 are formed. In an example, ball milling may be performed for a time ranging from about 10 minutes to about 50 hours. It is to be understood that longer ball milling leads to smaller particles. In an example, ball milling may be carried out in cryo conditions with liquid nitrogen, in order to easily break the larger particles into smaller particles.
- Phase separation (shown as “PS” in FIG. 1 ) of the composite particles 20 is then thermally induced.
- the amorphous lithium storage material 12 ′ will thermodynamically precipitate out from the composite particle 20 .
- Thermally induced phase separation in the examples disclosed herein may be accomplished at a temperature ranging from about 300° C. to about 900° C.
- the composite particles 20 may be exposed to annealing for a time ranging from about 30 minutes to about 100 hours, and annealing may take place in a vacuum furnace, a vacuum oven, or another suitable heating mechanism. In an example, the annealing also takes place in a protected environment, such as an argon or nitrogen environment.
- Phase separation results in the formation of phase separated composite particles, an example of which is shown at reference numeral 22 in FIG. 1 .
- the phase separated composite particles 22 include a matrix of the amorphous phase lithium storage material 12 ′ having the immiscible material 14 embedded therein. These particles are shown in FIG. 1 .
- the pores resulting from these phase separated composite particles 22 will be relatively small and will be surrounded by an interconnected matrix of the amorphous lithium storage material 12 ′.
- the phase separated composite particles include a matrix of the immiscible material 14 having the amorphous phase lithium storage material 12 ′ embedded therein. These particles are not shown in FIG. 1 . It is to be understood that pores resulting from these phase separated particles will be larger and interconnected.
- phase separated composite particles 22 are exposed to a chemical etching process, as shown at “E” in FIG. 1 .
- Any suitable etchant may be used that will remove the immiscible material 14 while leaving the amorphous lithium storage material 12 ′ substantially unaffected.
- chemical etching is performed using an acid, such as hydrochloric acid (HCl), sulfuric acid (H 2 SO 4 ), and nitric acid (HNO 3 ). Exposing the phase separated composite particles 22 to the acid removes the immiscible material 14 and forms pores 24 in the amorphous lithium storage material 12 ′. The pores 24 form in those areas previously occupied by the immiscible material 14 .
- the size of the pores 24 will depend, at least in part, on the atomic ratio of the lithium storage material 12 to the immiscible material 14 . In an example, the size of the pores 24 ranges from about 5 nm to about 1 ⁇ m.
- Acid exposure and immiscible material 14 removal results in the formation of the porous, amorphous lithium storage material particles 10 .
- These particles 10 may be washed, for example, using deionized water.
- the particles 10 include the amorphous lithium storage material 12 ′ as a matrix and pores 24 formed in the matrix. As described herein, in some instances, larger and more interconnected pores may be formed among a matrix of silicon nanoparticles.
- the average size of the particles 10 ranges from about 100 nm to about 20 ⁇ m.
- FIG. 2 another example of a method for making the porous, amorphous lithium storage material is schematically depicted.
- This example of the method utilizes a chemical vapor condensation method to make the composite particles 20 .
- a precursor 11 to the lithium storage material 12 and a precursor 13 to the immiscible material 14 are selected.
- Precursors 11 may include precursors to silicon or precursors to germanium-metal alloys.
- Precursors 13 may include precursors to tin (Sn), aluminum (Al), silver (Ag), indium (In), or iron (Fe).
- Examples of the silicon precursors 11 include 2,4,6,8,10-pentamethylcyclopentasiloxane (CH 3 SiHO) 5 , pentamethyldisilane (CH 3 ) 3 SiSi(CH 3 ) 2 H, silicon tetrabromide (SiBr 4 ), silicon tetrachloride (SiCl 4 ), tetraethylsilane Si(C 2 H 5 ) 4 , and 2,4,6,8-tetramethylcyclotetrasiloxane (HSiCH 3 O) 4 .
- CH 3 SiHO pentamethyldisilane
- SiBr 4 silicon tetrabromide
- SiCl 4 silicon tetrachloride
- HSiCH 3 O 2,4,6,8-tetramethylcyclotetrasiloxane
- tin precursors 13 examples include dibutyldiphenyltin [CH 3 (CH 3 ) 3 ] 2 Sn(C 6 H 5 ), hexaphenylditin(IV) (C 6 H 5 ) 3 Sn, tetraallyltin (H 2 C ⁇ CHCH 2 ) 4 Sn, tetrakis(diethylamido)tin(IV) [(C 2 H 5 ) 2 N] 4 Sn, tetrakis(dimethylamido)tin(IV) (CH 3 ) 2 N, tetramethyltin Sn(CH 3 ) 4 , tetravinyltin Sn(CH ⁇ CH 2 ) 4 , tin(II) acetylacetonate C 10 H 14 O 4 Sn, tricyclohexyltin hydride (C 6 H 11 ) 3 SnH, trimethyl(phenylethynyl)tin C 6 H 5 C ⁇ CS
- the selected precursors 11 and 13 are delivered via respective carrier gases 9 , 9 ′ into a heating zone HZ.
- An example of a suitable carrier gas 9 , 9 ′ includes argon plus about 5% hydrogen gas (H 2 ).
- the atomic ratio of the amorphous lithium storage material 12 ′ and the immiscible material 14 in the composite particles 22 may be varied, in this example, by controlling the carrier gas 9 , 9 ′ flow rate for the respective precursors 11 , 13 .
- a higher flow rate for the carrier gas 9 , 9 ′ including one of the precursors 11 , 13 will increase the atomic ratio of the corresponding material 12 ′, 14 in the composite particles 22 .
- a higher flow rate is used for the carrier gas 9 than for the carrier gas 9 ′, more of the lithium storage material precursor 11 will be introduced and the resulting composite particles 22 will include more of the amorphous lithium storage material 12 ′.
- the atomic ratio in this example will affect the morphology of the lithium storage material matrix and the size of the pores 24 in a similar manner to what was discussed in reference to FIG. 1 .
- the precursors 11 , 13 are exposed to a predetermined temperature, which, in an example, is above 1000° C. Within the heating zone HZ, the precursors 11 , 13 are reacted with one another to form an alloy vapor of the lithium storage material 12 and the immiscible material 14 .
- the precursors 11 , 13 carried by respective gases 9 , 9 ′ are a silicon precursor and a tin precursor.
- the alloy vapor formed in the heating zone HZ is a SiSn alloy vapor.
- the alloy vapor is then delivered to the cooling zone CZ, which is set to a predetermined temperature.
- the predetermined temperature of the cooling zone CZ is below about ⁇ 20° C.
- the alloy vapor condenses into the composite particles 20 .
- the cooling zone CZ provides rapid solidification, and the resulting lithium storage material 12 ′ in the composite particles 20 is amorphous.
- the composite particles 20 may be in powder form.
- the composite particles 20 are then subjected to phase separation PS and etching E. These processes may be accomplished as previously described in reference to FIG. 1 . These processes result in the formation of the porous, amorphous lithium storage material particles 10 .
- the examples of the method may also include applying a passivation layer on a surface of the particles 10 .
- This passivation layer may aid in suppressing decomposition of the electrolyte used in the lithium ion battery, and may prevent lithium loss in the solid electrolyte interphase formed on the pore surface of the lithium storage material particles 10 .
- the passivation layer include Al 2 O 3 , SiO 2 , TiO 2 , ZrO 2 , AlF 3 , C, TiN, AlN, ZrN, or other like materials.
- the passivation layer may be applied using any suitable vapor deposition technique, such as atomic layer deposition (ALD).
- the vapor may penetrate into some of the pores 24 , and thus the passivation layer may form on the pore 24 surface(s) and also on the particle's exterior surface.
- the thickness of the passivation layer may be controlled to be under 10 nm so that extra impedance is not introduced into the battery cell(s). It is to be further understood that the passivation layer will not change the morphology of the amorphous lithium storage material particles 10 .
- the porous, amorphous lithium storage material particles 10 disclosed herein may be used in anodes. These anodes may be particularly suitable for use in lithium ion batteries for the reasons mentioned herein.
- the anode includes the porous, amorphous lithium storage material particles 10 , sodium alginate, and graphene.
- the sodium alginate may be used to bind the particles 10 and the graphene together.
- the graphene may be desirable because it acts as a conductive additive, exhibits favorable lithium insertion and deinsertion characteristics, and can store lithium in quantities that produce a relatively high energy density.
- Binders other than sodium alginate may be used, including, for example, polyvinylidene fluoride (PVDF), poly(acrylic acid), carboxymethylcellulose, polyacrylonitrile, polyethylene oxide, polyethylene, polypropylene, polytetrafluoroethylene (PTFE), polybutadiene, polystyrene, polyalkyl acrylates and methacrylates, ethylene-(propylene-diene-monomer)-copolymer (EPDM) rubber, copolymers of styrene and butadiene, and mixtures of these polymers.
- PVDF polyvinylidene fluoride
- PTFE polytetrafluoroethylene
- EPDM ethylene-(propylene-diene-monomer)-copolymer
- Other conductive additives may be used instead of, or in addition to the graphene. Examples of other suitable conductive additives include carbon black, carbon nanotubes, conductive polymers, or combinations thereof.
- the anode includes from about 30 wt % to about 80 wt % of the particles 10 , from about 10 wt % to about 20 wt % of the binder, and from about 10 wt % to about 20 wt % of the conductive additive.
- the anode includes about 64 wt % of the particles 10 , about 15 wt % of the sodium alginate or other binder(s), and about 21 wt % of the graphene or other conductive additive(s).
- An example of the anode including the porous, amorphous lithium storage material particles 10 as shown in FIG. 3 at reference numeral 26 .
- FIG. 3 illustrates an example of a secondary lithium ion battery 100 .
- the battery 100 generally includes the anode 26 , a cathode 26 , a microporous polymer separator 30 sandwiched between the two electrodes 26 , 28 , and an interruptible external circuit 32 that connects the anode 26 and the cathode 28 .
- Each of the anode 26 , the cathode 28 , and the microporous polymer separator 30 are soaked in an electrolyte solution capable of conducting lithium ions.
- the microporous polymer separator 30 which operates as both an electrical insulator and a mechanical support, is sandwiched between the anode 26 and the cathode 28 to prevent physical contact between the two electrodes 26 , 28 and the occurrence of a short circuit.
- the microporous polymer separator 30 in addition to providing a physical barrier between the two electrodes 26 , 28 , ensures passage of lithium ions (identified by the black dots and by the open circles having a (+) charge in FIG. 3 ) and related anions (identified by the open circles having a ( ⁇ ) charge in FIG. 3 ) through the electrolyte solution filling its pores. This helps ensure that the lithium ion battery 100 functions properly.
- a negative-side current collector 26 a and a positive-side current collector 28 a may be positioned in contact with the anode 26 and the cathode 28 , respectively, to collect and move free electrons to and from the external circuit 32 .
- the lithium ion battery 100 may support a load device 34 that can be operatively connected to the external circuit 32 .
- the load device 34 may be powered fully or partially by the electric current passing through the external circuit 32 when the lithium ion battery 100 is discharging. While the load device 34 may be any number of known electrically-powered devices, a few specific examples of a power-consuming load device include an electric motor for a hybrid vehicle or an all-electrical vehicle, a laptop computer, a cellular phone, and a cordless power tool.
- the load device 34 may also, however, be a power-generating apparatus that charges the lithium ion battery 100 for purposes of storing energy. For instance, the tendency of windmills and solar panels to variably and/or intermittently generate electricity often results in a need to store surplus energy for later use.
- the lithium ion battery 100 can include a wide range of other components that, while not depicted here, are nonetheless known to skilled artisans.
- the lithium ion battery 100 may include a casing, gaskets, terminals, tabs, and any other desirable components or materials that may be situated between or around the anode 26 and the cathode 28 for performance-related or other practical purposes.
- the size and shape of the lithium ion battery 100 may vary depending on the particular application for which it is designed. Battery-powered automobiles and hand-held consumer electronic devices, for example, are two instances where the lithium ion battery 100 would most likely be designed to different size, capacity, and power-output specifications.
- the lithium ion battery 100 may also be connected in series and/or in parallel with other similar lithium ion batteries to produce a greater voltage output and current (if arranged in parallel) or voltage (if arranged in series) if the load device 34 so requires.
- the lithium ion battery 100 can generate a useful electric current during battery discharge by way of reversible electrochemical reactions that occur when the external circuit 32 is closed to connect the anode 26 and the cathode 28 at a time when the anode 26 contains a sufficiently higher relative quantity of intercalated lithium.
- the chemical potential difference between the cathode 28 and the anode 26 (ranging from approximately 2.5 to 5.0 volts, depending on the exact chemical make-up of the electrodes 26 , 28 ) drives electrons produced by the oxidation of intercalated lithium at the anode 26 through the external circuit 32 towards the cathode 28 .
- Lithium ions which are also produced at the anode 26 , are concurrently carried by the electrolyte solution through the microporous polymer separator 30 and towards the cathode 28 .
- the electrons flowing through the external circuit 32 and the lithium ions migrating across the microporous polymer separator 30 in the electrolyte solution eventually reconcile and form intercalated lithium at the cathode 28 .
- the electric current passing through the external circuit 32 can be harnessed and directed through the load device 34 until the intercalated lithium in the anode 26 is depleted and the capacity of the lithium ion battery 100 is diminished.
- the lithium ion battery 100 can be charged or re-powered at any time by applying an external power source to the lithium ion battery 100 to reverse the electrochemical reactions that occur during battery discharge.
- the connection of an external power source to the lithium ion battery 100 compels the otherwise non-spontaneous oxidation of intercalated lithium at the cathode 28 to produce electrons and lithium ions.
- the electrons, which flow back towards the anode 26 through the external circuit 32 , and the lithium ions, which are carried by the electrolyte across the microporous polymer separator 30 back towards the anode 26 reunite at the anode 26 and replenish it with intercalated lithium for consumption during the next battery discharge cycle.
- the external power source that may be used to charge the lithium ion battery 100 may vary depending on the size, construction, and particular end-use of the lithium ion battery 100 .
- Some suitable external power sources include a battery charger plugged into an AC wall outlet and a motor vehicle alternator.
- the anode 26 includes the porous, amorphous lithium storage material particles 10 .
- These particles 10 are the lithium host material that can sufficiently undergo lithium insertion and deinsertion while functioning as the negative terminal of the lithium ion battery 100 .
- the anode 26 may also include a binder material to structurally hold the porous, amorphous lithium storage material particles 10 together, and an electron conduction material (i.e., conductive additive), such as the previously mentioned graphene.
- the negative-side current collector 26 a may be formed from copper or any other appropriate electrically conductive material known to skilled artisans.
- the cathode 28 may be formed from any lithium-based active material that can sufficiently undergo lithium insertion and deinsertion while functioning as the positive terminal of the lithium ion battery 100 .
- the cathode 28 may also include a polymer binder material to structurally hold the lithium-based active material together.
- One common class of known materials that can be used to form the cathode 28 is layered lithium transitional metal oxides.
- the cathode 28 may include an active material intermingled with a polymeric binder and mixed with a high surface area carbon, such as acetylene black, to ensure electron conduction between the current collector 28 a and the active material particles of the cathode 28 .
- the active material may be made of at least one of spinel lithium manganese oxide (LiMn 2 O 4 ), lithium cobalt oxide (LiCoO 2 ), a nickel-manganese oxide spinel [Li(Ni 0.5 Mn 1.5 )O 2 ], a layered nickel-manganese-cobalt oxide [Li(Ni x Mn y Co z )O 2 ], or a lithium iron polyanion oxide, such as lithium iron phosphate (LiFePO 4 ) or lithium iron fluorophosphate (Li 2 FePO 4 F).
- the polymeric binder may be made of at least one of polyvinylidene fluoride (PVdF), an ethylene propylene diene monomer (EPDM) rubber, or carboxymethyl cellulose (CMC)).
- PVdF polyvinylidene fluoride
- EPDM ethylene propylene diene monomer
- CMC carboxymethyl cellulose
- Other lithium-based active materials may also be utilized besides those just mentioned. Examples of those alternative materials include lithium nickel-cobalt oxide (LiNi x Co 1-x O 2 ), aluminum stabilized lithium manganese oxide spinel (Li x Mn 2-x Al y O 4 ), and lithium vanadium oxide (LiV 2 O 5 ).
- the positive-side current collector 28 a may be formed from aluminum or any other appropriate electrically conductive material known to skilled artisans.
- the electrolyte solution may be a non-aqueous liquid electrolyte solution that includes a lithium salt dissolved in an organic solvent or a mixture of organic solvents. Skilled artisans are aware of the many non-aqueous liquid electrolyte solutions that may be employed in the lithium ion battery 100 as well as how to manufacture or commercially acquire them.
- lithium salts may be dissolved in a variety of organic solvents such as cyclic carbonates (ethylene carbonate, propylene carbonate, butylene carbonate), linear carbonates (dimethyl carbonate, diethyl carbonate, ethylmethylcarbonate), aliphatic carboxylic esters (methyl formate, methyl acetate, methyl propionate), ⁇ -lactones ( ⁇ -butyrolactone, ⁇ -valerolactone), chain structure ethers (1,2-dimethoxyethane, 1-2-diethoxyethane, ethoxymethoxyethane), cyclic ethers (tetrahydrofuran, 2-methyltetrahydrofuran), and mixtures thereof.
- organic solvents such as cyclic carbonates (ethylene carbonate, propylene carbonate, butylene carbonate), linear carbonates (dimethyl carbonate, diethyl carbonate, ethylmethylcarbonate), aliphatic carboxylic esters (methyl formate, methyl
- the microporous polymer separator 30 includes, or in some examples, is a membrane, and this membrane may be formed, e.g., from a polyolefin.
- the polyolefin may be a homopolymer (derived from a single monomer constituent) or a heteropolymer (derived from more than one monomer constituent), and may be either linear or branched. If a heteropolymer derived from two monomer constituents is employed, the polyolefin may assume any copolymer chain arrangement including those of a block copolymer or a random copolymer. The same holds true if the polyolefin is a heteropolymer derived from more than two monomer constituents.
- the polyolefin may be polyethylene (PE), polypropylene (PP), a blend of PE and PP, or multi-layered structured porous films of PE and/or PP.
- the membrane of the microporous polymer separator 30 may be formed from another polymer chosen from polyethylene terephthalate (PET), polyvinylidene fluoride (PVdF), polyamides (Nylons), polyurethanes, polycarbonates, polyesters, polyetheretherketones (PEEK), polyethersulfones (PES), polyimides (PI), polyamide-imides, polyethers, polyoxymethylene (e.g., acetal), polybutylene terephthalate, polyethylenenaphthenate, polybutene, polyolefin copolymers, acrylonitrile-butadiene styrene copolymers (ABS), polystyrene copolymers, polymethylmethacrylate (PMMA), polyvinyl chloride (PVC), polysiloxane polymers (such as polydimethylsiloxane (PDMS)), polybenzimidazole (PBI), polybenzoxazo
- PET
- the membrane of the microporous separator 30 may be chosen from a combination of the polyolefin (such as PE and/or PP) and one or more of the polymers for the separator 30 listed above.
- the microporous polymer separator 30 may contain a single layer or a multi-layer laminate fabricated from either a dry or wet process.
- a single layer of the polyolefin may constitute the entirety of the microporous polymer separator 30 membrane.
- a single layer of one or a combination of any of the polymers from which the microporous polymer separator 30 may be formed may constitute the entirety of the separator 30 .
- multiple discrete layers of similar or dissimilar polyolefins and/or polymers for the separator 30 may be assembled into the microporous polymer separator 30 .
- a discrete layer of one or more of the polymers may be coated on a discrete layer of the polyolefin for the separator 30 .
- the polyolefin (and/or other polymer) layer, and any other optional polymer layers may further be included in the microporous polymer separator 30 as a fibrous layer to help provide the microporous polymer separator 30 with appropriate structural and porosity characteristics.
- Still other suitable polymer separators 30 include those that have a ceramic layer attached thereto, and those that have ceramic filler in the polymer matrix (i.e., an organic-inorganic composite matrix).
- a thin film of SiSn was formed using a sputtering technique.
- silicon and tin were co-deposited as a composite thin film in a Gamma 1000 sputtering system.
- the amorphous silicon and tin phase segregated, resulting in phase separated regions of pure amorphous silicon and pure tin.
- a SEM of the phase separated thin film is shown in FIG. 4 . Silicon is the darker phase and tin is the brighter phase.
- Porous, amorphous silicon particles were formed via the method disclosed herein. Silicon and tin present in an atomic ratio of 75:25 were melted together. The mixture was rapidly solidified using melt spinning to form an amorphous silicon/tin composite, and this composite was subjected to ball milling to form amorphous silicon/tin composite particles. The amorphous silicon/tin composite particles were subjected to annealing to phase separate the amorphous silicon from the tin. Etching was performed with a 1M HCl solution in order to remove the tin from the amorphous silicon. This formed amorphous, porous silicon particles. A SEM of one amorphous, porous silicon particle is shown in FIG. 5 . This figure (from left to right across the page) is about 2,000 nm (i.e., 2 ⁇ m) of the porous silicon particle. The darker areas in FIG. 5 are pores that were formed within the silicon matrix.
- the cycling performance of the amorphous, porous silicon particles was tested and compared to the cycling performance of comparative amorphous silicon/tin particles (i.e., particles that were not exposed to the etching step). Electrodes were made using the amorphous, porous silicon particles and the comparative amorphous silicon/tin particles.
- the electrode including the amorphous, porous silicon particles is referred to as “Sample Electrode” and the comparative electrode including the amorphous silicon/tin particles is referred to as “Comparative Electrode”.
- the current efficiency of Sample Electrode and Comparative Electrode was also calculated based upon the ratio between charge and discharge capacity. These results are also shown in FIG. 6 . As illustrated, the current efficiency results for Sample Electrode are much higher than the current efficiency results for Comparative Electrode. As such, the Sample Electrode including the amorphous, porous silicon particles disclosed herein exhibited improved current efficiency.
- ranges provided herein include the stated range and any value or sub-range within the stated range.
- a range from about 100 nm to about 20 ⁇ m should be interpreted to include not only the explicitly recited limits of about 100 nm to about 20 ⁇ m, but also to include individual values, such as 500 nm, 1.5 ⁇ m, 12 ⁇ m, etc., and sub-ranges, such as from about 325 nm to about 15 ⁇ m; from about 750 nm to about 10 ⁇ m, etc.
- “about” is utilized to describe a value, this is meant to encompass minor variations (up to +/ ⁇ 5%) from the stated value.
Abstract
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US20140272578A1 (en) | 2014-09-18 |
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